Reinforced reel

ABSTRACT

A paperboard reel especially suitable for ribbon, lace and the like is made of paperboard and has a unique folding pattern for the various panels so that only one piece of paperboard has to be used and that each flange of the reel has at least two and as much as four thicknesses of material. The structure is foldable from a blank to a flat shipping construction which can be erected to its final configuration.

United States Patent Hanson et al. 1 Oct. 1, 1974 [5 REINFORCED REEL 2,368,594 1/1945 Hawkins 242/71.8 x

1 1 Wallace Springfield; Leo 22231322 35 $11Effiijiiiif" :3:1:.. iJ/i1 8. Paul Delude, chlcopee Falls, both of 3,104,077 9/1963 Struble 242 1 18.8 Mass. [73] Assignee: Champion International Primary Examinep'cemfi Mautz Corporation, Hamilton, Ohio Attorney, Agent, or Firm-Gardiner, Sixbey, Bradford & Carlson [22} Filed: June 9, 1972 [2]] Appl. No.: 261,483 [57] ABSTRACT A paperboard reel especially suitable for ribbon, lace [52] US. Cl. 242/71.8, 242/118.8 and th k s mad of paperboard and has a unique [51] Int. Cl B6511 75/14 f ng p tt n for the various panels so that only one [58] Field of Search 242/71.8, 118.8, 118.7, piece f p per oard has to be used and that each 242/1 1&4, 77, 1 18, 74 flange of the reel has at least two and as much as four thicknesses of material. The structure is foldable from [56] References Cited a blank to a flat shipping construction which can be UNITED STATES PATENTS erected to its final configuration. 1,052,303 2/ 1913 Aven 242/118.8 12 Claims, 5 Drawing Figures T1)? f V V V n 11D L 29 1 O l7 I i I [,9 g I l i I 1 I l 1 l i i 1 1 I l l fss '31 [25 |1||l1 I i r lH ip l |b L5 2 H E 2 7 i l l l I I I ll Q & 1, 1: 1 1', 24

= ll 1 1i: i '1 '1 1 1 1 n I l l l l I l7 I8 I) 1 G j o .o T

l'lj T T 29 PATENIEDHBI H 3.838.602- SHEU 2W 2 REINFORCED REEL BACKGROUND AND SUMMARY OF INVENTION This invention relates to improvements in reels made of one piece of foldable material. One aspect of the invention relates to improved reels made of paperboard or the like. Another aspect of the invention relates to an improved reel wherein the side panels have additional layers of material provided as reinforcement.

Reels made according to the present invention are suitable for storing elongated lengths of materials such as ribbon, lace and the like in connection with which usage of the invention will without being limited thereto be described.

The prior art is best exemplified by US. Pat. No. 2,477,333 issued on July 26, 1949 to William Hawkins which discloses a reel made from a single blank but had no positive means formed from the blank to help the reel maintain its erected condition. Hawkins did have tabs, but they were not positive in that they lacked mechanical interlocking or connecting means. Other attempts at making reels of this character have been numerous and include structures where flanges are stapled to a box-like member, or some other built-up structure from several pieces is employed: Greisman Pat. No. 2,436,861 is representative of numerous patents of this group.

In the making of the ribbon reels in connection with which this invention is described, it is highly desirable to be able to make the reel so that it can be shipped in a flat unitary condition and erected to its final shape at the time it is prepared for use, e.g., when ribbon, embroidery and the like are to be wrapped thereon. The machine stresses of winding materials on to such a reel, plus those of shipping and handling later on, require a structure that is easy to erect, rigid in service, light in weight, and easy to dispose of.

One of the co-inventors of the present invention has filed a patent application Ser. No. 80,870, now abandoned, relating to improved reels having certain features such as end flaps on the hubs and reinforcement of certain specific portions of the flanges of the reel.

The present invention has for an object the making of a reel from asingle paperboard blank which can be folded in such a manner than reinforcement is available across the entire area of each side panel or reel flange, yet providing a structure that can be folded from a blank to a flat shipping construction and later on erected to its final configuration.

It is an object of the present invention to provide a reel made from a single piece of material.

It is a further object of the present invention to provide a reel having improved reinforcement on its flanges.

Other objects and advantages and features of the present invention will become apparent from the following description when read in conjunction with the drawings wherein:

FIG. 1 is a plan view of a blank for making a reel according to the present invention and as seen from the inside surface of the blank;

FIG. 2 is a section taken along 2-2 of FIG. I showing the adhesive pattern on the inside and outside surfaces respectively;

FIG. 3 is an isometric view of reel erected from the blank of FIGS. 1 and 2;

FIG. 4 shows the folding arrangement for the blank of FIGS. 1 and 2 as seen along sections 4-4 of FIG. 3;

FIG. 5 shows the reel of FIG. 4 in a partially erected state.

Referring first to the version of FIGS. 1 5, a blank 1 is used to form the erected reel 2. The blank (FIG. 1) has a series of panels separated from each other, as is a common practice in the art, by score lines or (where dictated by the type of material) by perforated or cutscore lines. The panels as seen in FIG. I and read- .ing from right to left are an anchor panel 4, a first hub panel 5, a glue panel 6, a major partial reinforcing panel 7, a first outer side panel 9, a first minor partial reinforcing panel 10, a second hub panel 11, a second minor partial reinforcing panel 12, a second outer side panel and a third side panel for reinforcing l6.

Shaft holes 17 are cut out of the first and second outer side panels, the third side panel, and major partial reinforcing panel 9, l5, l6 and 7 respectively. These shaft holes are for receiving'the shafts on a ribbon winding machine so that the reel can be loaded on said machine, rotated rapidly and filled up with ribbon and thereby prepared for market. The glue and anchor panels are foreshortened by being cut out or cut away at 18, 19 respectively in such a way that these panels will not extend across the shaft holes 17 when the reel is erected. Alternatively the anchor and glue panels could have shaft holes cut out of them and extend the full length. However, this has been demonstrated to be a less satisfactory construction due to the small amount of material between such a hole and the edges of the glue or anchor panels respectively.

At each end of the first and second hub panels 5, 11 are hub flaps 20, 23 respectively which are foldable inwardly of the reel toward and in respective under-oroverlapping relationship with the corresponding flap 23, 20 from the other hub panel. In narrow reels (under about 3 A: inches wide) the hub flaps 23 are preferably flared outwardly as shown in exaggerated fashion in FIG. 1 so that they jam or wedge themselves tightly against the reel flanges (e.g. sides 9, 15, 16) and keep the reel erect. Wide reels (over 8inches wide) use a tab and slot as described in applicatin Ser. No. 80,870. The length of the hub flaps is more than one-half the thickness T (FIGS. 1, 4) of the hub whereby an overlapping relationship is insured. Preferably the hub flaps 20, 23 are substantially the thickness T (FIG. 1) whereby an almost complete overlap and enhanced strength is obtained. Various other cutouts 21, 22 are provided as desired (FIG. 1).

The panels are, as noted above, respectively separated one from another by score lines or cut score lines as the case may be. Reading from left to right as viewed in FIG. 1, the score lines 24, 25, 26, 27-, 29, 30, 31, 32 and 35 separate the respective panels in the order above named one from another and also thereby define the panel edges, fold lines, and common hinges shared one by another.

Other features which should be observed in FIG. 1 are a plurality of perforations 37 in glue panel 6. These perforations are preferably cut into the outside surface of the blank (the surface not seen in FIG. I) in order to improve glue penetration or the penetration of whatever adhesive material may be used. I

The adhesive pattern of FIG. 2 when read with Flg. 4 is believed to be self-explanatory. Alternatively the adhesive pattern could be reversed by applying the adhesive to the mating surfaces of those panels to which the adhesive bearing panels of FIG. 2 are intended to be adhered. While various adhesives can be used, ordinary water based glue of the sort normally used in carton making has been found quite satisfactory and is preferred.

The series of three panels comprising the first and second minor partial reinforcing panels 10, 12 and second hub panel 11 when taken together and as illustrated in FIG. 1 have substantially the size and shape of the outer side panels 9, 15. Also, the third side panel 16 has the shape of said outer side panels. The major partial reinforcing panel 7 when taken together with said first minor side panel and adhered in place (see FIG. 4 and below) is also of a size and shape sufficient to cover the inside surface of the first side panel 9 whereby at least a double thickness of material is available as a reinforcement to the panel 9.

The folding sequence and pattern preferred can best be understood by reference to FIGS. 1 and 4. Panels 7 and 9 are folded together along score line 27 and secured by the adhesive line on panel 9 (FIG. 2). Panel 6 is reverse folded along score 26 against the glue on major panel 7 and thus secured in the position (i.e. position when erected) shown in FIG. 4.

Panels and 16 are brought in to face-to-face contact and glued between their inside surfaces by reverse folding along score 35. Then first minor partial panel 10 is folded and glued inside face to inside face against first outer side panel 9 along score 29. Finally, the anchor panel 4 is folded reversely about score 24, inserted between second minor partial panel 12 and the third side panel 16, and secured to panels 12 and 16 by glue that has been applied to both sides of panel 4. In short, all panels are secured by adhesive such as glue to the one with which they are in face-to-face contact.

When erected in the manner just described a flattened blank of the sort found in FIG. 5 is formed. It can be erected by bending the blank about score lines 25, 26, 30 and 31 to thereby bring the hub panels into a substantially perpendicular relationship with the outer side panels. The hub panels, when the blank is flat, lie in approximately the same planes as the anchor and second minor panels 4, 12 respectively.

When the reel has been erected from the flattened position of FIG. 5 to that of FIG. 4, the end flaps 20, 23 are folded inwardly (FIG. 3) of the reel toward each other and into overlapping relationship to provide an enhanced rigidity.

When erected the reel has the shape and appearance as illustrated in FIG. 3.

By using the folding sequence and structure described above the reverse or inside surface (meaning inside or inwardly of the reel) is out of sight whence one only has to print on one side, the so-called outside surface. This permits the use of unbleached board or paperboard coated on one side or laminated on one side as the case may be. Regardless of the type of paperboard (which is the preferred material) the structure of FIG. 4 is preferred.

The invention claimed is:

I. An improved reinforced reel of one piece of foldable material with an outside surface and an inside surface comprising a major partial side reinforcing panel hingedly connected to one side of the first outer side panel and reversely folded against and secured to the inside surface of same;

said first minor partial side panel being hingedly connected to the opposite side of, reversely folded against the inside surface of, and secured to said first outer side panel;

said first minor side panel and said major side panel each being of a size and shape when taken together sufficient to cover the inside surface of said first side panel;

a glue panel hingedly connected by its opposite sides between said first hub panel and said major partial panel, respectively, and reversely folded against and secured by its own said outside surface to the outside surface of said major side panel;

an anchor reinforcing panel hingedly connected to said first hub panel on the edge opposite said glue panel and positioned and secured in a plane parallel to said second outer side panel;

said second hub panel being hingedly connected on one edge to the other edge of the first said minor side reinforcing panel and foldable from a flat position where it is facing toward said second outer side panel;

said second minor partial panel being hingedly connected between and to the other side of said second hub and said second outer side panel and reversely folded with its inside surface facing toward said second outer side panel;

whereby each side panel is reinforced by respective one of said minor partial panels and a respective one of said major and anchor panels.

2. An improved reel according to claim 1 wherein each hub panel has on each end a hub flap which is foldable inwardly of the reel toward and in over-orunderlapping relationship with the corresponding flap from the other hub panel.

3. An improved reel according to claim 1 further comprising a third side reinforcing panel of a size and shape like said second outer side panel and hingedly connected thereto along the edge opposite said second minor panel, which third panel is reversely folded to bring its inside surface against said inside surface of said second panel and said anchor panel is inserted between said third panel and said second minor side panel.

4. An improved reel according to claim 1 wherein said second hub panel and the two partial panels when taken together are substantially equal in size and shape to one of said side panels.

5. An improved reel according to claim 1 wherein said two minor partial panels are substantially the mirror images of each other.

6. An improved reel according to claim 1 further comprising a third side reinforcing panel hingedly connected to said second outer side panel along the edge opposite said second minor panel, which third panel is reversely folded to bring its inside surface against said inside surface of said second outer panel and is of a size and shape to at least cover said second outer panel inside surface from the reverse fold line to said second hub.

7. An improved reel according to claim 1 wherein said glue panel is perforated in order to enhance the penetration of adhesive materials thereinto.

8. An improved reel according to claim 1 wherein said glue and anchor panels have a cutout portion on each end such that they do not extend the full length or full dimension of the hub panels.

9. An improved reel according to claim 8 further having shaft holes in each of said side panels and wherein said cutouts shorten the glue and anchor panels so that they do not protrude into or across the shaft holes.

10. A blank for making an improved reinforced reel of one piece of foldable material having an inside surface and an outside surface comprising first and second outer side panels each shaped like the intended reel flange and having said outside surface facing outwardly of the reel and said inside surface facing inwardly of the reel, said panels being arranged in substantially parallel relationship relative to each other;

first and second hub panels arranged in respective substantially parallel planes which are substantially perpendicular to the planes in which said sidse panels are, said hubs both located between said side panels and spacing apart the side panels and their respective reinforcements;

first and second minor partial side reinforcing panels;

a major partial side reinforcing panel hingedly connected to one side of the first outer side panel and reversely folded against and secured to the inside surface of same;

said first minor partial side panel being hingedly connected to the opposite side of, reversely folded against the inside surface of, and secured to said first outer side panel;

said first minor side panel and said major side panel each being of a size and shape when taken together sufficient to cover the inside surface of said first side panel;

a glue panel hingedly connected by its opposite sides between said first hub panel and said major partial panel, respectively, and reversely folded against and secured by its own said outside surface to the outside surface of said major side panel;

an anchor reinforcing panel hingedly connected to said first hub panel on the edge opposite said glue panel and positioned and secured in a plane parallel to said second outer side panel;

said second hub panel being hingedly connected on one edge to the other edge of the first said minor side reinforcing panel and foldable from a flat position where it is facing toward said second outer side panel;

said second minor partial panel being hingedly connected between and to the other side of said second hub and said second outer side panel and reversely folded with its inside surface facing toward said second outer side panel;

whereby each side panel is reinforced by respective one of said minor partial panels and a respective one of said major and anchor panels.

11. A blank in accordance with claim 10 further comprising both said minor partial panels being the respective mirror images of each other and spaced apart by side second hub panel, the minor partial panels and said second hub panel together forming a structure of substantially the size and shape of any of said outer side panels.

12. An improved reel according to claim 2 wherein the overlapping ones of said hub flaps are flared outwardly. 

1. An improved reinforced reel of one piece of foldable material with an outside surface and an inside surface comprising first and second outer side panels each shaped like the intended reel flange and having said outside surface facing outwardly of the reel and said inside surface facing inwardly of the reel, said panels being arranged in substantially parallel relationship relative to each other; first and second hub panels arranged in respective substantially parallel planes which are substantially perpendicular to the planes in which said side panels are, said hubs both located between said side panels and spacing apart the side panels and their respective reinforcements; first and second minor partial side reinforcing panels; a major partial side reinforcing panel hingedly connected to one side of the first outer side panel and reversely folded against and secured to the inside surface of same; said first minor partial side panel being hingedly connected to the opposite side of, reversely folded against the inside surface of, and secured to said first outer side panel; said first minor side panel and said major side panel each being of a size and shape when taken together sufficient to cover the inside surface of said first side panel; a glue panel hingedly connected by its opposite sides between said first hub panel and said major partial panel, respectively, and reversely folded against and secured by its own said outside surface to the outside surface of said major side panel; an anchor reinforcing panel hingedly connected to said first hub panel on the edge opposite said glue panel and positioned and secured in a plane parallel to said second outer side panel; said second hub panel being hingedly connected on one edge to the other edge of the first said minor side reinforcing panel and foldable from a flat position where it is facing toward said second outer side panel; said second minor partial panel being hingedly connected between and to the other side of said second hub and said second outer side panel and reversely folded with its inside surface facing toward said second outer side panel; whereby each side panel is reinforced by respective one of said minor partial panels and a respective one of said major and anchor panels.
 2. An improved reel according to claim 1 wherein each hub panel has on each end a hub flap which is foldable inwardly of the reel toward and in over-or-underlapping relationship with the corresponding flap from the other hub panel.
 3. An improved reel according to claim 1 further comprising a third side reinforcing panel of a size and shape like said second outer side panel and hingedly connected thereto along the edge opposite said second minor panel, which third panel is reversely folded to bring its inside surface against said inside surface of said second panel and said anchor panel is inserted between said third panel and said second minor side panel.
 4. An improved reel according to claim 1 wherein said second hub panel and the two partial panels when taken together are substantially equal in size and shape to one of said side panels.
 5. An improved reel according to claim 1 wherein said two minor partial panels are substantially the mirror images of each other.
 6. An improved reel according to claim 1 further comprising a third side reinforcing panel hingedly connected to said second outer side panel along the edge opposite said second minor panel, which third panel is reversely folded to bring its inside surface against said inside surface of said second outer panel and is of a size and shape to at least cover said second outer panel inside surface from the reverse fold line to said second hub.
 7. An improved reel according to claim 1 wherein said glue panel is perforated in order to enhance the penetration of adhesive materials thereinto.
 8. An improved reel according to claim 1 wherein said glue and anchor panels have a cutout portion on each end such that they do not extend the full length or full dimension of the hub panels.
 9. An improved reel according to claim 8 further having shaft holes in each of said side panels and wherein said cutouts shorten the glue and anchor panels so that they do not protrude into or across the shaft holes.
 10. A blank for making an improved reinforced reel of one piece of foldable material having an inside surface and an outside surface comprising -first and second outer side panels each shaped like the intended reel flange and having said outside surface facing outwardly of the reel and said inside surface facing inwardly of the reel, said panels being arranged in substantially parallel relationship relative to each other; first and second hub panels arranged in respective substantially parallel planes which are substantially perpendicular to the planes in which said sidse panels are, said hubs both located between said side panels and spacing apart the side panels and their respective reinforcements; first and second minor partial Side reinforcing panels; a major partial side reinforcing panel hingedly connected to one side of the first outer side panel and reversely folded against and secured to the inside surface of same; said first minor partial side panel being hingedly connected to the opposite side of, reversely folded against the inside surface of, and secured to said first outer side panel; said first minor side panel and said major side panel each being of a size and shape when taken together sufficient to cover the inside surface of said first side panel; a glue panel hingedly connected by its opposite sides between said first hub panel and said major partial panel, respectively, and reversely folded against and secured by its own said outside surface to the outside surface of said major side panel; an anchor reinforcing panel hingedly connected to said first hub panel on the edge opposite said glue panel and positioned and secured in a plane parallel to said second outer side panel; said second hub panel being hingedly connected on one edge to the other edge of the first said minor side reinforcing panel and foldable from a flat position where it is facing toward said second outer side panel; said second minor partial panel being hingedly connected between and to the other side of said second hub and said second outer side panel and reversely folded with its inside surface facing toward said second outer side panel; whereby each side panel is reinforced by respective one of said minor partial panels and a respective one of said major and anchor panels.
 11. A blank in accordance with claim 10 further comprising both said minor partial panels being the respective mirror images of each other and spaced apart by side second hub panel, the minor partial panels and said second hub panel together forming a structure of substantially the size and shape of any of said outer side panels.
 12. An improved reel according to claim 2 wherein the overlapping ones of said hub flaps are flared outwardly. 